In response to several drawbar failures, which occurred on a military trailer negotiating rough cross-country terrain, TARDEC engineers analyzed, identified, corrected and tested an in-field repair kit using the tools of analytical and physical simulation. Using both the field-test data and simulator response data, a finite element analysis (FEA) model of the trailer frame and drawbar structure was developed. The FEA model showed several weak areas in the riveted Aluminum structure of the military trailer. The model was then used to evaluate recommended design changes to the trailer frame structure and drawbar. TARDEC’s Pintle Motion Base Simulator (PMBS) was used to validate the design changes in prototype. By iterating the process between the FEA model and the PMBS, a robust, cost effective field repair kit was developed and shown to be durable using both analytical and physical simulation methods in a cooperative effort.